Bolens 608 manual

IMPORT ANT : READ SAFETY RULES AND INSTRUCTIONS CAREFULL Y P R IN T E D IN U . S . A . F O RM N O . 770 - 1 0131 A Warning: This unit is equipped with an internal combustion engine and s hould not be used on or near any unimprov ed forest- covered, brush-covered or grass -covered land unless the engine’s exhaust sy stem is equipped with a spark a[...]

2 SECT ION 1: TABL E OF CONT ENTS PAGE FINDING Y OUR MODEL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CALLING CUSTOMER S U PPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IMPORTANT SAFE O PERATION PRACT[...]

3 SECTION 4: IMPORTANT SAFE OPERATION PRACTICES WARN ING: THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH, IF NOT FOLLOWED, COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS. READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OP E RATE YOUR LAWN MOWER. FAILURE TO COMPLY WITH THESE INSTRUCTIONS M [...]

4 • Disengag e all attac hment clutche s, thoroughl y depress the brake pedal , and shift into neutral before attemptin g to start engi ne. • Your mowe r is desig ned to c ut normal r esidential grass o f a height no more than 10". Do not attempt to mow t h rough unu sually tall , dry grass (e.g., pasture) or p iles of dry leave s. Debris [...]

5 • Keep all n uts, bolts and s crews tight to be su re the equipme nt is in safe w orking conditi on. • Never tamper wi th safe ty de vices . Check t heir proper opera tion regularly. U se all guards as instructe d in this ma nual. • After st riking a foreign obj ect, stop the engin e, remove the wire from the spark pl ug and thoroughly insp[...]

6 Slope Gauge 15 ° SIGHT AND HOLD THIS LEV EL W ITH A VERT ICAL TREE A POWER PO LE A CORNER OF A BUILDING OR A FE NCE POST F O L D O N D O T T E D L I N E , R E P R E S E N T I N G A 1 5 ° S L O P E USE THIS PAGE AS A GUIDE TO DETERMINE SLOPES WHERE YOU MAY NOT OPERATE SAFELY. Do not m ow on incl ines wit h a s lope in exce ss of 1 5 degr ees (a [...]

7 SECTION 5: ATT ACHMENTS & ACCESSORIES NOTE: Your trac tor is NOT de signe d for use with any type of gr ound-eng aging attachments (e.g. till er, plow). Use of this type of eq uipme nt WILL void the tractor ’s warrant y. SECTION 6: TRA CTOR SET-UP A TT A CHING THE B A TTER Y CABLES NOTE: The posi tive b attery termi nal i s marked Pos. ( +)[...]

8 SECTI ON 7: CON TROLS Figure 3 A Ignitio n Switch F PTO (Power Tak e-Off) Le ver B Throttl e Contr ol Lever G Drive Peda l C Choke Co ntrol ( if so equ ipped) H Brake Ped al D Indica tor Mo nitor I Parking B rake B utton E Lift Lever J Shift Lev er A C F I J E G H NOTE: Steering Wheel not shown for clarit y P B D A M P S NOTE: A ny refer ence in [...]

9 IGNITION SWITCH To start the engine , insert k ey into the ignition switc h and turn clock wise to th e START po sitio n. Releas e key to t h e ON position o nce en gine ha s fired. Se e Figure 4. Refer to STA R TING THE ENGI NE in the OPERA TION sec tion of th is manu al fo r detai led startin g instr ucti ons. The ig nition switch is also used [...]

10 LIFT LEVER The lift lever is used to change the operating posi tion (height ) of the cutting deck . To operate, move the lever to the left, then place in the notch best su ited for you r applic ation . PT O (PO WER T AKE-OFF) LEVER The PTO lever is loc ated on the left s ide of th e das h next to the s teering whee l. Move the P TO lev er forwar[...]

11 SECT ION 8: OP ERATIO N SAFETY INTERLOCK SWIT CHES This tra ctor is equip ped with a safety inter lock system for the prote ction of the opera tor. If the interlo ck system shoul d ever mal functi on, do no t operate the tractor. Contac t an authoriz ed dealer in your area . The safet y interl ock syst em prev ents th e engine from crank ing or [...]

12 NOTE: Do N OT leave the c hoke co ntrol ou t whil e operati ng the tra ctor. Doi ng so will resul t in a "r ich" fuel mix ture and caus e the en gine to r un poorly . ST OPPING THE ENGINE • Place the PTO lever in the di sengaged ( OFF) pos ition • Move the th rottle control int o the SLO W (turtle) position and allow the engin e to[...]

13 USING THE LIFT LEVER To ra ise the cuttin g dec k, mo ve th e lift lever to th e left, then p lace it in the notc h best suited for yo ur applic ation. Refer to SETT ING THE CUTTING HEIGHT earl ier in th is sectio n. ENGAGING THE PT O (PO WER T AKE-OFF) LEVER • Move th e throttle co ntrol lever to the FAST (rabb it) posi tion. • Move the PTO[...]

14 • Determin e the appro ximate distanc e nece ssary for prope r adjustme nt and proceed , if nece ssary , to the n ext s tep. • Loosen th e two j am nuts on th e rear si de of the de ck stab ilizer bracket. S ee F igure 7A . • Locat e the two lock nuts on the opposite s ide of the st abiliz er brac ket. Se e Figure 7A. Tighten th e lock nut[...]

15 BRAKE ADJUSTMENT If the t ractor doe s not come to a co mplete stop whe n the brak e pedal is comp letely d epresse d, or if th e tractor ’ s r ear wheel s can roll with the parki ng brak e applied , the brake i s in n eed o f adju stment . Th e brake d isc can be fo und on th e right side of the transm ission in th e re ar of th e t ractor. A[...]

16 CARBURET OR ADJUSTMENT WARN ING: If any adju stment s are made to the eng ine whi le the eng ine is running (e.g. carb uretor), dis engag e all clutche s and blad es. K eep clear of all moving par ts. Be careful of heate d surface s and muffler. NOTE: A dirt y air cl eaner will cau se an e ngine t o run roug h. Be certai n it is clea n and prope[...]

17 CUTTING DECK REMO V AL WARN ING: Be fore per forming any maintenan ce, mov e the PT O lever in to the disenga ged (OF F) posi tion, en gage th e parking br ake, turn the ignition k ey to the OFF pos ition and rem ove th e key f rom the switch t o avoi d accid ental starti ng . Seve ral attac hments are av aila ble for y our tractor . To mount so[...]

18 CHANGING THE DECK B EL T(S) All bel ts on you r tract or are s ubject t o wear and s hould be r eplaced if any signs of crac king, s hredding or rotting are presen t. IMPORTANT: The V- belts foun d on your trac tor are special ly desig ned to engag e and dis engag e safely. A substit ute (no n-OEM) V -belt can be dange rous by not dis engaging c[...]

19 Figure 15 CHANGING THE TRANSMISSION D RIVE BEL T(S) All bel ts on you r tract or are s ubject t o wear and s hould be r eplaced if any signs of crac king, s hredding or rotting are presen t. IMPORTANT: The V- belts foun d on your trac tor are special ly desig ned to engag e and dis engag e safely. A substit ute (no n-OEM) V -belt can be dange ro[...]

20 Lower Drive Belt NOTE: Prop er remo val of the low er driv e belt require s the rem oval of sever al tractor comp onents. Rea d through t he foll owing pro cedure prior to attempt ing it to determi ne if you fee l you co uld s uccessf ully c omplet e it. If you don ’ t, see an auth orized MTD ser vice d ealer to have the be lt ch anged. IMPORT[...]

21 Figure 17 Adjust the dr ive pedal afte r replac ing the drive belts on yo ur tractor , if ne cessar y, as fo llows: • Locate the speed contr ol asse mbly o n the unders ide of the steer ing s upport b racket. See Figure 1 8. Figure 18 • Remove b oth hair pin clips from th e pin whi ch is fa stened to t he sp eed con trol assemb ly ( be caref[...]

22 It is e xtremel y im portant that ea ch c utting blade edge be ground equa lly to m aintain proper blad e balance . An unbalanc ed bl ade will cause exces sive vibrat ion when r otatin g at hi gh speeds , may cause damage to the trac tor and resul t in per sonal in jury. The bla de can be tested by balan cing it on a blad e balan cer or ro und s[...]

23 SECTI ON 12: TROUBLESHOOT ING GUIDE T roub le Possible Cau se(s) Corrective Act ion Engine will not cran k Saf ety sw itch butto n not depresse d. Battery installed incorrec tly . Battery is dead or weak. Blow n fuse There a re three saf ety s witches in the star ting circ uit of your unit: the bra ke peda l s witch, the PT O swit ch and the sea[...]

24 Models 607, 608 & 609 9 3 8 10 1 5 11 5 13 13 6 4 5 2 REF . NO . PA R T NO . DESCRIPTION 1 625-0051 Bulb /Sock et Headli ght Assemb ly 2 629-0944 Wiring Ha r ness w/o Re f. 14 3 629-0126 Harness Ada pter , #18 x 5 4 710-0599 Self-tapp ing Screw , 1/4-20 x .5 5 712-3006 He x Nut, 1/4-20 6 725-1426 Solenoi d, 12-volt, 100 Amp 7 725-1657A Sn ap[...]

25 Electrical System A2 WHITE RED A/C G REEN - PTO - L + S RUN 1 KEY SW 725-1741 OFF RUN 2 G+M+ A1 B+A1 B+A1 B AL T ER N A TO R AFTE RFIRE SOL ENOID MAGNETO ALTERN ATO R ST AR T E R A1 HEADLIG H TS GR OU ND PTO SW ITCH KEY SWITC H BRAKE SW ITCH SOLENO I D FUSE L+A2 REVERSE SW. SEAT SWITCH BATTER Y 725- 142 6 725- 165 7A 725-1 381 72 5- 164 3 STAR T[...]

26 Models 607 & 608 41 30 3 24 25 32 27 31 28 7 26 19 5 39 38 47 43 24 33 5 36 34 35 1 4 45 42 44 15 16 22 22 10 17 3 5 7 9 18 12 20 13 9 4 6 11 1 8 23 2 37 29 21 46 46[...]

27 REF . NO . PA R T NO . DESCRIPTION 1 683-0195 Brac ket Assemb ly 2 710-0528 He x Cap Scre w , 5/16-18 x 1.25 3 710-0599 Self-tapping Screw , 1/4-20 x .5 4 710-0751 He x Cap Scre w , 1/4-20 x .62 5 710-0895 Self-tapp ing Scre w , 1/4-15 x .75 6 710-0896 Scre w , 1/4-15 x .7 5 7 710-0924 Phillip s Pa n Screw , 1/4-20 x .7 5 8 7 12-02 71 Hex Sems N[...]

28 Model 609 26 3 24 25 28 23 22 32 4 9 7 6 4 10 33 31 12 16 14 3 11 20 20 1 15 1 30 20 21 15 29 1 5 21 18 18 27 19 17 20 8 8 2 15[...]

29 Tractor Body REF . NO . PA R T NO . DESCRIPTION 1 710-0604A Se lf-tapping Scre w , 5/16-18 x .625 2 710-0788 Self-tapp ing Screw , 1/4-20 x 1.0 3 710-0895 Self-tapp ing Screw , 1/4-15 x .75 4 710-1017 T orx Self-tappin g Screw , 5/16-18 x . 625 5 710-1238 Scre w , 5/16-18 x . 875 (Grade 5) 6 710-3217 T orx Screw , #8-32 x .375 7 712-0142 He x Nu[...]

30 Models 607, 608 & 609 36 6 32 11 43 40 42 28 35 37 33 36 41 39 38 31 14 8 13 9 17 21 22 10 20 12 23 21 22 24 6 2 8 14 18 25 19 6 5 3 4 16 9 7 17 15 5 19 8 14 6 6 1 34 26 30 31 44[...]

31 REF . NO . PA R T NO . DESCRIPTION 1 7 47-1 130 Deck Sta bil izer Ro d 2 6 83-0 197 Li ft Sh aft A ssem bly 3 7 11-0 332 Clevis Pin, .5 x . 78 4 7 12-0 206 Hex Nut , 1/ 2-13 5 7 12-0 431 Fl ang e Lock Nut , 3/ 8-16 6 7 12-3 004A Flan ge L ock Nut , 5/1 6-1 8 7 7 12-3 083 Hex Nut , 1/ 2-13 8 7 14-0 104 In ter n al Cot te r Pin 9 7 14-0 111 Cot te[...]

32 Models 607, 608 & 609 24 1 2 2 2 5 3 9 6 38 8 10 12 13 11 13 14 15 16 17 18 19 21 20 22 20 24 23 25 26 27 28 31 3 0 29 32 35 34 30 32 35 36 33 39 40 11 41 42 13 7 43 42 22 4 32 35 44 37[...]

33 REF . NO . PA R T NO . DESCRIPTION 1 683-0304 Low er F rame Asse mbly 2 710-0604A Self-tapp ing Screw , 16-18 x .625 3 783-0726A RH Piv ot Suppor t Brac ket 4 783-0727 LH Piv ot Support Brack et 5 783-0728 Piv ot Bar Brac ket 6 710-0514 He x Cap Scre w , 3/8-16 x 1 (Grade 5) 7 711-1409A LH Dr ag Link 8 711-1408 RH Dr ag Link 9 712-0240 Ja m N ut[...]

34 Models 607, 608 & 609 2 21 2 21 13 19 13 18 36 11 28 31 7 38 46 47 40 8 44 12 37 47 15 17 1 19 50 26 27 24 10 49 1 9 23 30 32 20 42 14 39 16 61 3 9 13 76 62 13 69 53 54 25 41 57 58 19 23 64 68 73 71 58 65 56 58 33 77 58 63 55 69 66 59 21 75 33 52 31 68 64 23 23 35 78 79 34 81 82 6 45 12 43 60 83 72 63 35 21 70 80 4 22 13 5 29 35 58 60 83[...]

35 REF . NO . PA R T NO . DESCRIPTION 1 783-1015 Shift Le ver Supp or t 2 17840 T ransaxle Mou nting Brac ket 3 618-0307C Single-s peed T rans m issio n Assembly 4 631-0009 Shifter Kno b 5 647-0045 Shift Le ver 6 656-0048 V ariable-s peed Pulley Assembl y 7 656-0051A T ransmission Pul ley , 8.5 x .5-36 8 683-0251 Doub le-idler Bra cket 9 710-0176 H[...]

36 Models 607, 608 & 609 Units with 618-0307C T ransmission ONL Y 31 12* 20 40 29 26 31 30 28 27 18 39 38 38 39 3 13 12c 15 8 17 24 23 2 1 16 7 12c 14 12c 9 10 12* 4 11 37 3 13 36 32 37 12* 34 12* 14 14 6 21 5 21 22 25 19 41[...]

37 REF . NO . PA R T NO . DESCRIPTION 1 618-0318 Clutc h Collar † 2 710-0788 Self-t apping Scr ew , 1/4-20 x 1.0 3 711-1274 Driv e Shaft 4 711-1280 Count er Shaft 5 713-0474 22-link Chain, #420 6 713-0478 14-tooth Sprock et 7 717-1422 Sproc ket Be vel Gear , 42/10 8 717-1565 29-tooth Spur Gear 9 717-1569 20-tooth Spur Gear 10 718-0652 Count er Sh[...]

38 Models 607, 608 & 609 42 1 50 13 4 14 15 16 18 19 11 5 12 5 38 6 7 8 9 6 1 7 10 57 2 53 54 55 56 28 51 48 26 16 45 44 58 40 41 52 39 36 29 33 25 34 31 32 23 33 46 47 27 49 30 (PT O belt f or 37 22 A A 42" de ck sho wn) 21 43 28 45 3 21 1 35 25 24 33 20 Hook sp r ing , Ref . 58, here 59[...]

39 REF . NO . PA R T NO . DESCRIPTION 1 712-0431 Flange Lock Nu t, 3/8-16 2 732-0996 Com pression Spring, 1.31 x 3.0 3 783-0733 Spacer C up , 1.5 OD 4 732-0997 Com pression Spring, . 66 OD x 1.5 5 710-0604A Self-tap ping Screw , 5/16-18 x .625 6 7 10-0 751 Hex Cap S cr ew , 1/4- 20 x .62 7 7 12-0 271 Hex Sems Nut, 1/4 -20 8 712-3044 Wing N ut, 1/4-[...]

40 Models 607, 608 & 609 42-inch Deck 46-inch Deck 52 49 49 14 14 58 67 75 67 68 56 53 9 30 29 35 25 23 77 74 19 30 29 35 38 21 27 38 22 31 7 15 54 73 65 15 64 32 55 50 72 15 51 71 76 57 50 57 57 57 17 12 17 15 59 62 62 24 2 4 32 3 2 19 19 61 46-inc h Deck Brake Asse mbly 44 45 46 43 47 35 29 30 15 12 14 36 9 14 36 1 19 25 9 24 24 32 32 17 35 2[...]

41 REF . NO . PA R T NO . DESCRIPTION 1 16606 Retainer Hook 2 618-0324 Spindle Assembly , 5.7 5 Dia. 3 683-0198C 42-i nch Deck Sh ell 4 683-0254 Dec k Adjustmen t Brac ket w / W eld Nut 5 683-0303 Deck Brake As sembly , 42-inch Decks 6 710-0520 He x Cap Scre w , 3/8-16 x 1.5 7 710-0528 He x Cap Scre w , 5/16-18 x 1.25 8 710-0604A Self-tappin g Scre[...]

42 Models 607, 608 & 609 Briggs & Stratton Briggs & Stra tton OHV V-Twin OHV Single 7 11 (for cho ke) 13 4 12 (for throt tle) 6 9 22 18 19 20 8 10 14 10 5 10 5 16 15 1 (deflecto r must face fo rward) 17 5 34 3 2 21 3 2 18 19 20 9 13 9 31 30 4 33 14 1 (deflec tor mu st face forwa rd) 6 18 20 2 7 29 32 21 28 3 25 9 3 3 5 35[...]

43 REF . NO . PA R T NO . DESCRIPTION 1 710-0148 Self-tappi ng Screw , #8-32 x .375 2 710-0599 Self-tappi ng Screw , 1/4-20 x .5 3 710-0604A Self-tappi ng Screw , 5/16-18 x .62 5 4 710-1237 Scre w , #10-32 x .625 5 710-1314 Sock et Cap Sc rew , 5/16-18 x .625 6 710-1315 Self-tappi ng Screw , 3/8-16 x 1.25 7 712-3017 He x Nut, 3/8-16 8 721-0460 Exha[...]

MANUF A CTURER ’ S LIMITED W ARRANTY FOR: The l imit ed wa rrant y set fort h be low is gi ven by MTD PRODUCTS INC ( “ MTD ” ) with respe ct to new m erchandise purchase d and used in the United States, i ts possessio ns and ter r itories. MTD war rants this prod uct against def ects in mate r ial and workman ship for a period of two (2) y ea[...]